Single component two-stage regulator

ABSTRACT

Disclosed is a cylindrical, single-component two-stage regulator for controlling a pressure and a flow rate of a gas. The regulator includes a housing for holding the two stages having an ingress adapted for connection to a source of gas at a high input pressure and an egress adapted for supplying gas at a lower output pressure than the high input pressure; a first stage for reducing the pressure of the gas from the high input pressure to a fixed intermediate pressure; and a second stage for reducing the pressure of the gas from the fixed intermediate pressure to the lower output pressure and regulating the flow rate of the gas out of the egress. One application of the present invention is for use in SCUBA (Self-Contained Underwater Breathing Apparatus) applications, where it replaces the traditional two-component user-adjustable regulator. The regulator may be made out of stainless steel, and is small enough to fit into a user&#39;s mouthpiece.

REFERENCE TO RELATED APPLICATIONS

This application is a CONTINUATION of and claims priority fromco-pending application U.S. Ser. No. 12/651,896 entitled “A SINGLECOMPONENT TWO-STAGE REGULATOR,” filed on Jan. 4, 2010, which itselfclaims priority from provisional application U.S. Ser. No. 61/247,943entitled “A COMBINED TWO-STAGE MICRO-REGULATOR DEVICE,” filed on Oct. 1,2009, the entirety of both of which are hereby incorporated by referenceherein.

FIELD OF THE INVENTION

This invention relates to an article for reducing the pressure of aninput gas to a useable output pressure, which output pressure ispredetermined at the factory. One application of the present inventionis for use in SCUBA (Self-Contained Underwater Breathing Apparatus)applications, where it replaces the traditional two-componentuser-adjustable regulator.

BACKGROUND OF THE INVENTION

One and two-stage regulators are used in a wide variety of applicationsto control the flow of compressed gas from a high-pressure side to alow-pressure side in a manner that provides gas pressures suitable forthe appropriate use at the application (low-pressure) side of theregulator. Various industries with applications requiring two-stagehigh-pressure breathable air regulators include SCUBA applications,medical oxygen therapy, emergency medical services, fire fighting,environmental hazard response, search and air rescue, among others.

In all of these applications, the purpose of the regulator is to take ahigh-pressure gas source, e.g. an air cylinder, and deliver the air orother gas to the user at useable pressure. To accomplish this, the gasmust pass through a pressure reduction regulator. In current practice,the first stage is placed on a yoke attached to the tank and the secondstage connects to the mouth piece as shown in FIGS. 1, 2 and 3. Thefirst-stage takes incoming high pressure gas from the cylinder andreduces it to an intermediate pressure that is greater than the ambientpressure. The second stage, which fits into the user's mouth or mask,receives the intermediate pressure from the two hose lines connecting tothe first stage and reduces it to a usable ambient pressure. Two hoselines are used for redundancy.

FIG. 1 shows a photograph of a traditional yoke 100 manufactured byJohnson Outdoors Inc. under the SCUBAPRO® name which forms the firststage of a traditional regulator. An inlet 101 receives gas from a tank(not shown) typically at 3,000 psi. Dual lines 105 carry output gas at areduced intermediate pressure, typically ranging from 120 to 180 psi.Knob 103 holds the yoke to the tank; a pressure gauge is connected vialine 107 and buoyancy control is connected via line 109.

FIG. 2 illustrates an example of a traditional two-component regulator200 (SCUBAPRO®) and described in U.S. Pat. No. 4,862,884 (see FIG. 1).First stage 201 of the regulator is connected to the second stage 203via a hose 205.

FIG. 3 illustrates an example of a traditional two-component regulator300 in operation used for SCUBA diving (SCUBAPRO®) and described in U.S.Pat. No. 7,171,980 (see FIG. 1). First stage 301 of the regulator isconnected to the second stage 303 via a hose 305. The first stage 301attaches to the tank, while the second stage 303 goes into the user'smouth.

FIG. 4 illustrates an example of a traditional flat-shaped piston 400used in the first stage to regulate pressure in a traditional regulator(SCUBAPRO®) and described in U.S. Pat. No. 7,171,980 (see FIG. 4). Thisschematic view shows the forces acting on a valve poppet while in anopen (top) and a closed (bottom) position during operation of theregulator. In the closed position (bottom), the pressure applied to theright side of the piston face, element 403, closes the piston againstthe valve poppet 401. In the open (top) position, when the pressurereduces, the piston moves into the containment area 407 and air pressureflows around the container wall 405.

There are numerous problems associated with traditional designs,depending upon the particular application. For example, in SCUBAapplications, the extreme cold encountered at deep diving depths maycause the first stage of the pressure regulators to freeze up andmalfunction. The brass and chrome coating materials tend to cause thepoppet valve to stick in the open or closed position at these coldtemperatures which endanger the life of the diver. Another issue withthese designs is that improper use of the adjustment knob could alsopose a danger by the end user accidently changing the pressure out ofthe safe operating pressure range. Typically, first stage regulatorsrequire two components and two lines for redundancy due to the safetyconcern of product failure.

Accordingly, it would be an advancement in the state of the art toprovide a two-stage micro-regulator by reducing the size of theregulator and eliminating the adjustment nozzle through fixed pressuresettings defined during the manufacturing process. It would be a furtheradvancement in the state of the art to produce both the first and secondstages in a single cylindrical component, which can fit inside a user'smask or mouth piece, which provides body heat, hence preventingfreezing.

BRIEF SUMMARY OF THE INVENTION

Accordingly, one embodiment of the present invention is asingle-component two or more stage regulator for controlling a pressureand a flow rate of a gas. The regulator includes a cylindrical housingfor holding the two stages having an ingress adapted for connection to asource of gas at a high input pressure and an egress adapted forsupplying gas at a lower output pressure than said high input pressure;a first stage for reducing the pressure of the gas from said high inputpressure to a fixed, factory pre-set intermediate pressure; and a secondstage for reducing the pressure of the gas from the fixed intermediatepressure to the lower output pressure and regulating the flow rate ofthe gas out of the egress. Additional stages maybe added in this designif a smaller diameter size is required. Currently with the use of twostages, the diameter of the cylindrical housing can be manufactured toapproximately 0.880 inches, which can easily fit into a traditionalmouth piece.

Another embodiment of the present invention involves a non-useradjustable factory set intermediate pressure through use of an electronwelded end cap.

Another embodiment of the present invention involves a first stagethrottle tube containing the ingress for receiving the source of gas atthe high input pressure.

Another embodiment of the present invention involves a first stagepiston having a plug on an ingress side and an egress side of apredetermined shape, where the first stage piston is adapted tooscillate to open and close a gap between the first stage throttle tubeand the first stage piston allowing gas to enter.

Another embodiment of the present invention involves a compressiblematerial disposed between the first stage throttle tube and the firststage piston adapted to allow the piston to oscillate between an openposition and a closed position.

Another embodiment of the present invention involves a plug made from acomposite material.

Another embodiment of the present invention involves a spring made froma compressible material.

Another embodiment of the present invention involves memory foam madefrom a compressible material such as, but not limited to, polypropylene.

Another embodiment of the present invention involves the first stagepiston oscillating in order to maintain the fixed intermediate pressure.

Another embodiment of the present invention involves the fixedintermediate pressure being determined by ratio of a surface area of theegress side of the first stage piston relative to a surface area of theingress side.

Another embodiment of the present invention involves a first stagecylinder sleeve that creates a tight seal around the first stagethrottle tube.

Another embodiment of the present invention involves a first stagecylinder end cap for holding the compressible material in place.

Another embodiment of the present invention involves one or more o-ringsadapted to create tight seals between each component.

Another embodiment of the present invention involves manufacturing theregulator from stainless steel.

Another embodiment of the present invention involves a second stage,which includes a second stage throttle tube controlling the ingress, asecond stage piston having a plug with an ingress end and a predefinedshaped egress end, and a compressible material.

Another embodiment of the present invention involves a second stagepiston oscillating in order to maintain the fixed output pressure.

Another embodiment of the present invention involves a spring attachedto a push plate to control an opening and closing of the second stagepiston.

Another embodiment of the present invention involves a second stagecylinder containing a factory set adjustment plate.

Another embodiment of the present invention involves a second stagecylinder end cap for sealing the factory set adjustment plate.

Yet another embodiment of the present invention involves a cylindrical,single component two-stage SCUBA regulator, comprising a cylindricalhousing for holding the two stages having an ingress adapted forconnection to a source of gas at a high input pressure and an egressadapted for supplying gas at a lower output pressure than said highinput pressure, a first stage for reducing the pressure of the gas fromsaid high input pressure to a factory pre-set intermediate pressure, anda second stage for reducing the pressure of the gas from said fixedintermediate pressure to the lower output pressure and for regulatingthe flow rate of the gas out of the egress.

Yet another embodiment of the present invention includes a method forregulating a pressure of a gas, including the steps of providing atwo-stage regulator having a cylindrical housing, receiving a source ofgas at a high input pressure, reducing pressure of the gas from saidhigh input pressure to a factory pre-set intermediate pressure, reducingthe pressure of the gas from said fixed intermediate pressure to a loweroutput pressure, and supplying the gas at the lower output pressure thansaid high input pressure.

Other embodiments of the present invention will become apparent in thedetailed description of the invention.

BRIEF DESCRIPTION OF THE DRAWINGS

The invention can best be understood in reference to the attacheddrawings in which:

FIG. 1 shows a photograph of an example of a traditional yoke, whichforms a first stage of a traditional two-stage regulator used in theSCUBA industry;

FIG. 2 illustrates an example of a traditional two-component regulator;

FIG. 3 illustrates another example of a traditional two-componentregulator used for SCUBA diving during operations;

FIG. 4 illustrates an example of a traditional piston used to regulatepressure in a first stage of a traditional regulator;

FIG. 5 illustrates an example of an assembled single-component two-stageregulator according to one embodiment of the present invention;

FIG. 6 a illustrates an expanded view of a first stage (top) and asecond stage (bottom) single component two-stage regulator according tothe principles of the present invention;

FIG. 6 b illustrates an assembled view of a first stage regulator in anopen (top) and a closed (bottom) positions;

FIG. 6 c illustrates an assembled view of a second stage regulator in anopen (top) and a closed (bottom) positions;

FIG. 6 d illustrates flow of gas through an assembled view of thecombined regulator in an open (top) and a closed (bottom) positions;

FIG. 7 shows a photograph of a U.S. one dollar bill for size reference(top), and an example of an assembled single component two-stageregulator (bottom) according to one embodiment of the present invention;

FIGS. 8-27 illustrate CAD drawings of each part of a single componenttwo-stage regulator according to just one embodiment of the presentinvention; and

FIG. 28 illustrates a method for regulating a pressure of a gasaccording to one embodiment of the present invention.

DETAILED DESCRIPTION OF THE INVENTION

What separates the design of the present invention from existing SCUBAtechnology is that the mouthpiece contains the entire assembly of thefirst and second stage regulator in a small form factor that actuallyincreases the allowable pressure tolerance. A higher pressure tolerancegreater than the traditional 3,000 psi enables the use of much smallertanks with the same, if not greater, amount of gas. A custom roboticmanufacturing process creates the regulator to a size capable of fittinginto a mouth piece as shown in FIG. 7 by comparison to the size of aU.S. one dollar bill. Instead of using brass-plated chrome, a customhigh-quality stainless steel alloy improves every aspect of the quality,size, and weight of the regulator. Since the regulator actually fitsinto the mouth piece of the user, the human body provides heat to theregulator, which eliminates the freezing issues associated with currentSCUBA designs. Due to the alloy and design, the regulator can easilyhandle the 3,000 psi pressure of a standard SCUBA tank or even higherpressures exceeding 10,000 psi from a custom-made tank.

The micro-regulator eliminates the need for an adjustment knobaltogether by incorporating a fixed intermediate-pressure design. Duringthe manufacturing process, different compressible materials (FIG. 6,element 1100) and pistons (FIG. 6, element 1200) change the pressuretolerances defined by the physical design elements of the components.For example, a regulator that would utilize a standard 3,000 psi tankwould have a different spring and piston than a regulator designed for acustom 10,000 psi tank. The shape and surface area ratio of the left andright side of the piston of element 1200 determine the outlet pressureof the first stage. A clear distinction is made between the existingflat piston design shown in FIG. 4 and the uniquely shaped piston(element 1200) used in the micro-regulator.

The fixed intermediate-pressure design set during the manufacturingprocess eliminates the danger of incorrectly adjusting above or belowthe ideal ambient pressure. The first stage of the regulator eliminatesthe need for an intermediate pressure hose that existing designsrequire. The oscillation of the first stage piston 1200 into and awayfrom the first stage throttle tube 800 allows the first stage to go fromthe high pressure at the tank to the factory preset fixed intermediatepressure. When the intermediate pressure falls below the factory presetpressure, there is a slight opening. When the fixed preset pressure isexceeded, the gap closes. The second stage reduces the fixedintermediate pressure to the useable ambient pressure as well asproviding flow control and purge mechanisms, which ensures that thediver can inhale and exhale naturally regardless of the depth.

The second stage throttle tube 1400, and second stage piston's 1700predefined shape and surface area, along with the compressible materialcharacteristics (elements 1100 and 1900), modify the factory definedoutput pressure 507. The second stage piston 1700 oscillates into andaway from the second stage throttle tube 1400 due to a compressiblematerial 1900, such as a spring or memory foam, in order to maintain thefactory defined output pressure 507. During manufacturing, the finetuning of the output pressure occurs using the second stage adjustmentnub 2400, which moves the second stage adjustment plate 2100 element.Once complete, the adjustment nub 2400 is permanently welded to preventthe end user from adjusting the output pressure 507. A second stageadjuster plate cap 2500 covers the weld to make the end piece flush. Thesecond stage wishbones shown in FIG. 27 allow the user to purge the maskthrough two separate valves, which allow the user to displace excesswater in the mask.

The metal assembly of parts is preferably a one piece construction. Themetal is preferably a high quality stainless steel, such as 316L, whichis used in the construction of the regulator.

FIG. 5 illustrates an example of a cylindrical single-componenttwo-stage regulator 500 assembled according to one embodiment of thepresent invention. High pressure gas enters at the ingress 501, passesthrough the first stage 505, where it is reduced to a factory assignedintermediate pressure, then enters the second stage 509, which reducesthe pressure to the useable ambient pressure as well as regulating theflow of gas through the egress 507. Ambient pressure outside of theregulator enclosure enters through holes 503. The wishbone 2700 utilizedfor purging purposes (not shown in this figure) attaches through holes511. Utilizing the ambient pressure of the user's mouth piece from theambient pressure holes 503 allows this regulator to work at any depth.

FIG. 6 a illustrates an expanded view of a first stage (top) and asecond stage (bottom) single component two-stage regulator according tothe principles of the present invention. Gas enters at ingress hole 501.Intermediate pressure gas is represented as element 615. Ambientpressure enters through holes 503. Gas exits at the useable low pressurethrough egress hole 507. Wishbones 2700 attach at 511 for purging.Descriptions of each part of the two-stage regulator shown, preferredmaterials, and reference to full drawings can be found in Table 1.Cylindrical casing elements 1300 and 1500 provide a tight seal aroundthe first and second stage regulators once electron beam welded duringassembly. The use of o-rings 2300 seal the internal components of theregulator stages within the cylindrical casing (elements 1300 and 1500).

TABLE 1 Parts of the single component two-stage regulator FIG. NumberPart Number Component Name/Description Preferred Material FIG. 8 800First Stage Throttle Tube Stainless Steel FIG. 9 900 First StageCylinder Sleeve Acetal FIG. 10 1000 First Stage End Cap/CylinderStainless Steel FIG. 11 1100 First Stage Compressible Material StainlessSteel or a memory foam (polypropylene) FIG. 12 1200 First Stage PistonStainless Steel 1201 - ingress holes 1203 - uniquely-shaped area toallow increased pressure to close the first stage piston FIG. 13 1300First Stage Cylinder/Housing Stainless Steel 1301 - ambient pressureholes FIG. 14 1400 2^(nd) Stage Throttle Tube/Mid Joint Stainless SteelFIG. 15 1500 Second Stage Cylinder/Housing Stainless Steel 1501 - egressholes FIG. 16 1600 Second Stage Piston Sleeve Acetal FIG. 17 1700 SecondStage Piston Stainless Steel FIG. 18 1800 First Stage Piston Shim AcetalFIG. 19 1900 2^(nd) Stage Compressible Material Stainless Steel or amemory foam (polypropylene) FIG. 20 2000 Second Stage Spring Push PlateAcetal FIG. 21 2100 Second Stage Adjustment Plate Acetal FIG. 22 2200Second Stage End Cap Stainless Steel FIG. 23 2300 O-Ring Elastomer FIG.24 2400 Second Stage Adjuster Nub Stainless Steel FIG. 25 2500 SecondStage Adjuster Plate Cap Acetal FIG. 26 2600 First Stage Piston SeatTorlon FIG. 27 2700 Second Stage Wishbone Stainless Steel

FIG. 6 b illustrates an assembled view of a first stage regulator in anopen (top) and a closed (bottom) positions according to the principlesof the present invention. Gas enters at ingress element 501.Descriptions of each part of the two-stage regulator shown, preferredmaterials, and reference to full drawings can be found in Table 1.

FIG. 6 c illustrates an assembled view of a second stage regulator in anopen (top) and a closed (bottom) positions according to the principlesof the present invention. Gas exits at a useable low pressure throughegress holes 507. The second stage piston 1700 remains closed by thesecond stage compressible material 1900 and the second stage push plate2000 until the intermediate pressure reaches the desired factory setoutput pressure and moves the piston open. Descriptions of other partsof the two-stage regulator shown, preferred materials, and reference tofull drawings can be found in Table 1.

FIG. 6 d illustrates flow of gas through an assembled view of a singlecomponent two-stage regulator according to the principles of the presentinvention. Gas enters at ingress holes 501 via a tank hose (not shown).The compressible material (for example, a spring) pushes outwards onto afirst stage piston. The gas pushes the first stage piston closed, whilethe compressible material pushes the first stage piston open. The secondstage piston 1700 oscillates due to a compressible material 1900, suchas a spring or memory foam, in order to maintain the factory definedoutput pressure 507.

FIG. 7 shows a photograph of a single component two-stage regulator(bottom), and a U.S. one dollar bill for size reference (top). As shownin FIG. 7, the unique single-component regulator is approximately thesize of a human mouth, easily fitting into a SCUBA mask or mouthpiece.

FIGS. 8-27 illustrate CAD drawings of each part of a single componenttwo-stage regulator according to just one embodiment of the presentinvention. Table 1 enumerates each component shown in FIGS. 8-27. Thedimensions, proportions, and materials of the components shown in FIGS.8-27 are illustrative of only a single embodiment of the presentinvention. The dimensions, proportions, and materials are shown forillustrative and explanatory purposes only, and are not intended tolimit the scope of the invention in any way, which is defined solely bythe appended claims.

FIG. 28 illustrates a flowchart of a process 2800 for regulating apressure of a gas. The process begins at step 2801. At step 2803, atwo-stage regulator having a cylindrical housing is provided. At step2805, a source of gas at a high input pressure is received. At step2807, the pressure of the gas is reduced from the high input pressure toa factory pre-set intermediate pressure. At step 2809, the pressure ofthe gas is further reduced from the fixed intermediate pressure to alower output pressure. At step 2811, the gas at the lower outputpressure is supplied for use. Finally, at step 2813 the process ends.

While the methods disclosed herein have been described and shown withreference to particular operations performed in a particular order, itwill be understood that these operations may be combined, sub-divided,or re-ordered to form equivalent methods without departing from theteachings of the present invention.

While the present invention has been particularly shown and describedwith reference to embodiments thereof, it will be understood by thoseskilled in the art that various other changes in the form and detailsmay be made without departing from the spirit and scope of the presentinvention.

1. A single component two-stage regulator for controlling a pressure ofa gas, comprising: a cylindrical housing for holding the two stageshaving an ingress adapted for connection to a source of gas at a highinput pressure and an egress adapted for supplying gas at a lower outputpressure than said high input pressure; a first stage for reducing thepressure of the gas from said high input pressure to a factory pre-setfixed intermediate pressure; and a second stage for reducing thepressure of the gas from said fixed intermediate pressure to the loweroutput pressure at the egress.
 2. The regulator of claim 1, wherein thefixed intermediate pressure is not adjustable by the user.
 3. Theregulator of claim 1, wherein the first stage comprises: a first stagethrottle tube containing the ingress for receiving the source of gas atthe high input pressure; a first stage piston having a plug on aningress side and an egress side of a predetermined shape, wherein thefirst stage piston is adapted to oscillate to open and close a gapbetween the first stage throttle tube and the first stage pistonallowing gas to enter; and a compressible material disposed between thefirst stage throttle tube and the first stage piston adapted to allowthe piston to oscillate between an open position and a closed position.4. The regulator of claim 3, wherein the plug is made from a compositematerial.
 5. The regulator of claim 3, wherein the compressible materialis a spring.
 6. The regulator of claim 3, wherein the compressiblematerial is a memory foam.
 7. The regulator of claim 3, wherein thefirst stage piston oscillates in order to maintain the fixedintermediate pressure.
 8. The regulator of claim 3, wherein a surfacearea of the egress side of the first stage piston relative to a surfacearea of the ingress side determines the fixed intermediate pressure. 9.The regulator of claim 3, wherein the first stage further comprises: afirst stage cylinder sleeve that creates a tight seal around the firststage throttle tube.
 10. The regulator of claim 3, wherein the firststage further comprises: a first stage cylinder end cap for holding thecompressible material in place.
 11. The regulator of claim 3, whereinthe first stage further comprises: one or more o-rings adapted to createtight seals between each component.
 12. The regulator of claim 1,wherein the regulator is manufactured from stainless steel.
 13. Theregulator of claim 1, wherein the second stage comprises: a second stagethrottle tube controlling an ingress; a second stage piston having aplug with an ingress end and a predefined shaped egress end; and acompressible material.
 14. The regulator of claim 13, wherein the secondstage piston oscillates in order to maintain a fixed output pressure.15. The regulator of claim 13, wherein a spring attached to a push platecontrols an opening and a closing of the second stage piston.
 16. Theregulator of claim 13, wherein a second stage cylinder contains afactory set adjustment plate.
 17. The regulator of claim 16, wherein ashape and a surface area of the second stage piston and the factory setadjustment plate determine the output pressure.
 18. The regulator ofclaim 16, wherein a second stage cylinder end cap seals the factory setadjustment plate.
 19. A SCUBA regulator sized to fit into a mouthpiece,comprising: a cylindrical housing for holding a two-stage regulatorhaving an ingress adapted for connection to a SCUBA tank at a high inputpressure and an egress adapted for supplying gas to a user at a loweruseable pressure; a first stage for reducing the pressure of the gasfrom said high input pressure to a factory pre-set intermediatepressure; and a second stage for reducing the pressure of the gas fromsaid fixed intermediate pressure to the lower useable pressure at theegress and for purging gas out of the mouthpiece.
 20. A method forregulating a pressure of a gas, comprising: providing a two-stageregulator having a cylindrical housing; receiving a source of gas at ahigh input pressure; reducing pressure of the gas from said high inputpressure to a factory pre-set fixed intermediate pressure; reducing thepressure of the gas from said fixed intermediate pressure to a loweroutput pressure; and supplying the gas at the lower output pressure.